Atmospheric Processing Module for Mars Propellant Production

Transcription

1 Atmospheric Processing Module for Mars Propellant Production Anthony Muscatello, NASA KSC Tracy Gibson, James Captain, Robert Athman, Matthew Nugent, Steven Parks, and Robert Devor, ESC KSC The 16 th Annual Mars Society Convention The University of Colorado, Boulder August 15-18,

2 Outline Introduction Project Goals Design and Construction Testing Current Status NASA Plans for Mars ISRU 2

3 Introduction ISRU In Situ Resource Utilization ISPP: In Situ Propellant Production Produce Mars Sample Return launch propellant Demonstrate to reduce risk for human Mars missions MARCO POLO - Mars Atmosphere and Regolith COllector/PrOcessor for Lander Operations The Mars Atmospheric Processing Module (APM) Mars CO 2 Freezer Subsystem Sabatier (Methanation) Subsystem Collect, purify, and pressurize CO 2 Convert CO 2 into methane (CH 4 ) and water with H 2 Other modules mine regolith, extract water from regolith, purify the water, electrolyze it to H 2 and O 2, send the H 2 to the Sabatier Subsystem, and liquefy/store the CH 4 and O 2 3

4 What is MARCO POLO? Mars Atmosphere and Regolith COllector/PrOcessor for Lander Operations First generation integrated Mars soil and atmospheric processing system with mission relevant direct current power 10 KW Fuel Cell for 14 hrs of daytime operations 1KW Fuel Cell for 10 hrs of night time operations Demonstrates closed loop power production via the combination of a fuel cell and electrolyzer. The water we make and electrolyze during the day provides the consumables for the 1KW Fuel Cell that night Planned for remote and autonomous operations 4

5 Lander at Critical Design Review Atmo Processing Module: CO2 capture from Mixed Mars atmosphere (KSC) Sabatier converts H2 and CO2 into Methane and water (JSC) C&DH/PDU Module: (JSC) Central executive S/W Power distribution Soil Processing Module: Soil Hopper handles 30kg (KSC) Soil dryer uses CO2 sweep gas and 500 deg C to extract water (JSC) Liquefaction Module: (TBD) Common bulkhead tank for Methane and Oxygen liquid storage Water Processing Module: (JSC) Currently can process 520g/hr of water (max 694 g/hr) 3m x 3m octagon lander deck Water Cleanup Module: (KSC) Cleans water prior to electrolysis Provides clean water storage Life Detection Drill: (ARC-Honeybee) Replaces excavator mockup Takes core samples Provides some feed to Soil Dryer 1KW Fuel Cell and consumable storage (JSC & GRC) Using metal hydride for H2 storage due to available 1KW No Flow Through FC (GRC) 5 10KW FC not shown (JSC)

6 APM Goals/Requirements Collect and purify 88 g CO 2 /hr (>99%) From simulated Martian atmosphere 10 mbar; 95% CO 2, 3% N 2, 2% Ar Supply 88 g CO 2 /hr at 50 psia to the Sabatier reactor Convert CO 2 to 31.7 g CH 4 /hr and 71.3 g H 2 O/hr Operate autonomously for up to 14 hr/day Minimize mass and power Fit within specified area and volume 9,000 cm 2 hexagon 44 inches tall (112 cm, same as Water Processing Module) 107 cm 30.5 cm 107 cm Support MARCO POLO production goals of 444 g CH 4 /day and 1.77 kg O 2 /day (50% of O 2 ) for a total of 2.22 kg propellant/day Sufficient for a Mars Sample Return Mission 30.5 cm 6

7 Atmospheric Processing Module Sabatier Reactor Methane Dryer (Future) CO 2 ballast tanks not shown Chiller CO 2 Freezers Electrochemical Methane Separator [Replaced by Recycle Pump and Membrane Module] Vacuum Pump Mixed Mars Gas Input 7

8 Atmospheric Processing Operations Ballast tank CO 2 freezer 95% CO 2, 3% N 2, 2% Ar at 10.8 mbar Mars Mix Ballast tank CO 2 freezer 88 g/hr CO 50 PSI Sabatier Reactor (<600 deg C) 16.2 g/hr H 2 2 g/hr H g/hr H 2 O 31.7 g/hr CH 4 2 g/hr H 2 Electrolysis Stacks CH 4 /H 2 Separator H 2 O CH 4 H 2 Condenser Water Cleanup Module H 2 O Water Processing Module H 2 O CH 4 H 2 O CH 4 Dryer CH 4 CH 4 storage 8

9 CO 2 Freezer Final Design Emergency Vent Copper Cold Head CO 2 Freezer Tank #1 < 1 mbar 10.8 mbar Pressure Equalizer Valves CO 2 Ballast Tank T, PI CO 2 Pump T, PI 15 psig FC T Cryocooler #1 CO 2 Ballast Tank T, PI Chiller FM Mars Atmosphere 95% CO2, 3% N2, 2% Ar ~700 psig max Emergency Vent CO 2 Freezer Tank #2 < 1 mbar Cryocooler #2 Copper Cold Head T T, PI 10.8 mbar Vacuum Pump < 1 mbar inlet Up to 1 bar outlet Vent to Atmosphere/Hood 2 - Cryocoolers with Freezing Chambers 11 - Magnetic Latching Solenoid Valves 1 - Chiller with 4-Way Dual Solenoid Valve 1 - Vacuum Pump 1 - CO2 Pump 2 - CO2 Ballast Tanks 2 - Vacuum Back Pressure Regulators 3 - Pressure Relief Valves 1 - Flow Controller 1 - Flow Meter 3 - Thermocouples and 2 RTDs Pressure Transducers, etc.

10 CO 2 Freezer CO 2 Tanks Chiller Cryocoolers Avionics Copper Cold Head 10

11 Sabatier Subsystem Design To be added: Recycle Pump (Custom KNF N VDC) Air Products Membrane Module 11

12 Sabatier Subsystem JSC Sabatier Reactor Recycle Pump Membrane Module (Cut- Away View) 12

13 Atmospheric Processing Module 13

14 Water Cleanup Module (KSC) Tested with Water Processing Module at JSC last summer Used to recycle fuel cell water from the MMSEV to H 2 and O 2 MMSEV = Multi Mission Space Exploration Vehicle Gas-Gas HEx Gas-Gas HEx Condenser Membrane Clean Water Tank Dirty Water Tank Liquid-Liquid HEx DI Resin Freon Reservoir Coolant Reservoir Membrane separator not included in the final version 14

15 Lander and Soil Processing Module (KSC) Van Townsend (KSC/ESC) with MARCO POLO lander and Soil Processing Module (under construction) RASSOR (Regolith Advanced Surface Systems Operations Robot) will feed the hopper 15

16 CO 2 Freezer Testing Avg. Capture Rate = g/hr at 1.2 SLPM (1.4 hr test) Avg. Sublimation Rate = 93.8 g/hr (1.4 hr test) Avg. Capture Fraction = 76% Exceeds 88 g/hr requirement Better performance than test stand! % CO2 Capture CO2 Collection Rate, g/hr 88 g/hr Requirement CO2 Sublimation Rate in 1.4 hr, g/hr Mars Atmosphere Simulant Flow Rate, SLPM 16

17 JSC Sabatier Testing JSC Testing was successful (>99% conversion at 4.5:1 H 2 /CO 2 ratio) First three KSC tests overheated >600 C One test did not overheat (top) at 250 sccm CO 2 vs. 747 sccm desired (1000 sccm H 2 ) Duplicate run did overheat (middle) Twelve tests at various flow rates overheated Two tests with simulated recycle gases (N 2 /H 2 /CO 2 = 6.0/3.35/0.75 SLPM) was slower to overheat, but still did so (bottom) Decided to build redesigned Sabatier reactor 17

18 Current Status CO 2 Freezer Subsystem essentially complete Fully automated and fluid system functional Need replacement CO 2 pump to reach 100 psi for overnight storage capability (KNF NPK09 rocking piston pump leaks - normal for design) Chiller being returned by vendor after inspection showed no defects Sabatier Subsystem Fluid system automated and functional New reactor being designed Based on proprietary design by Pioneer Astronautics Need to add recycle pump and membrane module Testing needed to verify operation Plan integrated MARCO POLO testing in Swamp Works Big Bin regolith bin Date TBD Testing will support Mars ISRU design studies Long Term Goal is to continue to refine the ISRU technologies for potential 2018 robotic Mars mission using a SpaceX Red Dragon capsule as part of an Ames-led science effort 18

19 NASA Plans for Mars ISRU Mars 2020 Mission Science Definition Team Report (July 1, 2013): The highest priority HEOMD payload is the demonstration of CO 2 capture and dust size characterization for atmospheric ISRU p. 63 Collect atmospheric carbon dioxide. Analyze dust (size, shape, number) during CO 2 collection. Produce small quantities of oxygen and analyze its purity (option). p. 61 Reduces risk for human missions and possible Mars sample return p. 61 p

20 Future MARCO POLO Historic Marker? 20

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